Solid oxide fuel cell systems with hot zones having improved reactant distribution

ABSTRACT

A Solid Oxide Fuel Cell (SOFC) system having a hot zone with a center cathode air feed tube for improved reactant distribution, a CPOX reactor attached at the anode feed end of the hot zone with a tail gas combustor at the opposing end for more uniform heat distribution, and a counter-flow heat exchanger for efficient heat retention.

STATEMENT OF GOVERNMENT INTEREST

This invention was made with Government support under governmentcontract DE-FC36-04G014318 awarded by the Department of Energy toProtonex Technology LLC. The Government may have certain rights in theinvention.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The subject disclosure relates to fuel cells, and more particularly tosolid oxide fuel cell systems having hot zones with improved reactantdistribution, more uniform heat distribution, and/or more efficient heatretention.

2. Background of the Related Art

Referring to FIG. 1, a schematic view of a generator 110 with a hot zone112 is shown. The generator 110 has an electrochemical stack or solidoxide fuel cell (SOFC) 120 typically operating at temperatures above600° C., Several other support components are also operating at elevatedtemperature.

Commonly, the SOFC 120 is located within a hot environment to facilitateproper operation. In some instances, an external furnace could provide ahot environment but the furnace size, weight, and power consumption maynegate most practical benefits in many applications. For example, forpractical portable power generation applications, the SOFC 120 ispreferably able to maintain stack temperature and operating environmentin a compact and efficient package.

To accomplish maintaining the endothermic components at sufficienttemperature, the SOFC 120 has an area of integration of the elevatedtemperature components, referred to as the hot zone 112. The hot zone112 is insulated to reduce heat loss and maintain the desired operatingtemperature. The components of the hot zone 112 include a fuelprocessing reactor such as, without limitation, a catalytic partialoxidation (CPOX) reactor 114 for converting the system feed hydrocarbonfuel to a hydrogen and carbon monoxide rich feed for the stack 120 ofthe generator 110. For example, the CPOX reactor may convert ahydrocarbon fuel like propane or diesel to hydrogen and carbon monoxideby reaction with air over a catalyst. The CPOX product gases are thenfed to the anode side of the SOFC stack 120. For liquid fuels, the feedhydrocarbon fuel is readied for the CPOX reactor 114 by using anatomizer or vaporizer.

The hot zone 112 also includes an exothermic tail gas combustor 116 thatburns the remaining unutilized fuel from the stack 120 to reduce COemissions and also to utilize the remaining fuel energy in the form ofheat within the hot zone 112. For example, some hydrogen and carbonmonoxide are oxidized with oxygen that is transported across the SOFCelectrolyte (not shown explicitly) from the air on the cathode side ofthe SOFC stack 120. This remaining hydrogen and carbon monoxide aremixed with cathode exhaust in the tail gas combustor 116 for burning ina homogenous flame and/or over a catalyst.

The tail gas combustor exhaust enters a recuperator 118 where the gas iscooled by exchanging heat with the incoming cathode air. The recuperatorheat exchanger 118 maintains heat within the hot zone 112 bytransferring heat from the SOFC exhaust gas to the inlet stack air.

A power conditioning unit 124 also connects to the electrochemical stack120. A CPOX air blower 126 provides air to the CPOX reactor 114. A fuelpump 130 expels fuel from a fuel tank 128 to the vaporizer 122. Acathode blower 132 provides air to the recuperator 118 and cathode sideof the electrochemical stack 120.

The approach of FIG. 1 has several disadvantages. Each componentrequires piping to connect to the neighboring component. This plumbingrequires a high temperature sealing method such as brazing or welding, avery labor intensive and extremely difficult to automate process. Eachhot zone component also requires special features for braze or weldjoints to the attached piping. These special features are typicallymachined, and result in high cost components.

Further, some stack components are ceramic, and sealing metal-to-ceramicjoints is difficult such as shown in U.S. Patent Application PublicationNo. 2004/0195782 published on Oct. 7, 2004. The hot CPOX reactor 114 andtail gas combustor 116 are located away from the electrochemical stack120, which slows heating at startup. Assembling and joining thesecomponents in close proximity is difficult and requires packing a largevolume in a small space. Consequently, the support components canundesirably occupy as much hot zone volume as the electrochemical stack120. The inability to closely integrate the hot zone components leads toa low hot zone power density and uneven distribution of heat. Further,the large insulation surface around the hot zone 112 may increase heatloss.

High fuel utilization is particularly desirable for high generatorefficiency. The generator 110 cannot alone utilize the fuel unless theSOFC 120 is impracticably large. Thus, the performance of the tail gascombustor 116 is particularly important and serves as a source ofthermal energy that can be used for other needs. For instance, thethermal energy can keep the stack 120 at operating temperature andbalance heat losses through insulation and system exhaust.

U.S. patent application Ser. No. 12/006,688, filed on Jan. 4, 2008 (the'688 Application), also recognized many shortcomings of the prior artand provided improvements thereto. The '688 Application disclosed asolid oxide fuel cell system including a main plate, an inner cylinderattached to the main plate, an intermediate cylinder attached to themain plate such that the intermediate cylinder contains a cathode airstream, and an outer cylinder attached to the main plate. An exhaustannular gap is formed between the intermediate and outer cylinders suchthat hot exhaust gases co-flow through the exhaust annular gap and heatis transferred from the hot exhaust gases to the cathode air stream.

The hot zone 112 provides key functions to support the SOFC stackoperation including even temperature distribution throughout the stackvolume, even flow distribution of fuel gases to the anodes of all cellsin the stack and even flow distribution of air to the cathodes of allcells in the stack. Combustion of unutilized fuel in the stack exhaustmay also occur in the hot zone. Preferably, there are minimal thermallosses through conduction across the hot zone boundaries and minimalthermal losses through hot exhaust gases.

Another function of the hot zone 112 is to maintain stack operatingtemperature within an appropriate range. Stack operating temperaturemust be high enough to maximize electrolyte ionic conductivity andprevent carbon formation. Stack temperature must not be too high,however, to avoid lowering the open circuit potential, increasing theelectrolyte electrical conductivity, and initiating thermal degradationof cell or system materials. These temperature limits depend on thematerials used in the cells and stack, and an exemplary idealtemperature range might be between 700 and 800° C. Keeping all cells inthe stack 120 within such a temperature range requires a design thatminimizes thermal gradients in the stack.

U.S. Pat. No. 6,492,050, issued on Dec. 10, 2002 to Sammes, attempted toprovide an integrated solid oxide fuel cell and reformer. However, theheat exchanger design of Sammes has little surface area, which leads topoor performance. Also the Sammes system is thermally unbalanced notonly axially but radial temperature variation is also significant withregions of stagnant air.

SUMMARY OF INVENTION

It is an object of the subject technology to provide a SOFC system witha CPOX reactor configured such that the CPOX reactor is run at adesirable operating temperature and the CPOX catalyst temperature is notexcessively high. It is another object of the subject technology toutilize a CPOX reactor with an atomizer to allow feeding liquid fuels tothe SOFC system. Preferably, the CPOX reactor tube diameter and lengthcan be freely set. In order to accommodate any fuel feed mechanism, theCPOX reactor may be located in, partially in or outside the hot zone.

It is still another object of the subject technology to locate the CPOXreactor at a boundary of, partially outside or even outside of the hotzone to reduce or control preheating and enable liquid fuel feed.Preferably, the feed end of the CPOX reactor is easily accessed and notobstructed by other hot zone structures.

It is still another object of the subject technology to have a moreuniform temperature distribution within the stack. In one embodiment,the CPOX reactor and tail gas combustion heat sources are on opposingends of the stack.

It is another object of the subject technology to have a more uniformradial temperature distribution in the stack.

It is yet another object of the subject technology to provide uniformair flow on the cathode side in the radial directions while minimizingregions of stagnant air. One embodiment uses a central feed tube.

It is still another object of the subject technology to increase thermalrecuperation effectiveness by using counter-flow heat exchanger designs.

In one embodiment, the subject technology is directed to a solid oxidefuel cell system including an elongated stack having a first end and asecond end. The stack includes a plurality of tubular cells, each cellhaving an inner radius configured as an anode electrode portion and anouter radius configured as a cathode electrode portion. A support plateretains the stack and a feed can couples to the support plate to form ananode feed plenum adjacent the first end of the stack. A catalyticpartial oxidation (CPOX) reactor is in fluid communication with theanode feed plenum for receiving a hydrocarbon fuel and air mixture toprovide a hydrogen and carbon monoxide rich fuel anode feed stream tothe anode feed plenum, wherein the anode feed plenum is in fluidcommunication with the stack so that the anode feed stream passesthrough the tubular cells to become an anode exhaust.

The cathode air feed tube may extend from the first end to the secondend of the stack to distribute radial flow evenly along the length ofthe tubular cells. The feed tube may also define a plurality of holesdesigned and positioned to achieve a desired air flow distribution. Forexample, the plurality of holes may increase in size toward the secondend of the stack. The solid oxide fuel cell system may further includean exhaust end tube sheet for further supporting the stack as well as anexhaust can that forms an anode exhaust plenum with the exhaust end tubesheet. The exhaust can may define an anode exhaust hole. A cathodechamber can depends from the support plate and surrounds the stack andthe exhaust can while defining an exhaust gas hole near the anodeexhaust hole to form a region in which the anode exhaust and the cathodeexhaust mix to form a mixed exhaust stream. The solid oxide fuel cellsystem may also include a tail gas combustor catalyst at the second endof the stack for oxidizing unutilized fuel in the mixed exhaust stream.It is envisioned that the second end of the stack may be without acatalyst but still form a tail gas combustion zone wherein homogenouscombustion occurs.

In another embodiment, the subject technology is directed to a solidoxide fuel cell system including an elongated stack having a first endand a second end, the stack including a plurality of tubular cells, eachcell having an inner radius configured as an anode and an outer radiusconfigured as a cathode, and a feed tube extending substantiallycentrally through the stack for providing a cathode feed stream acrossthe tubular cells to become a cathode exhaust. The solid oxide fuel cellmay also include a feed can coupled to the stack to form an anode feedplenum adjacent the first end of the stack, and a CPOX reactor ill fluidcommunication with the anode feed plenum for receiving a hydrocarbonfuel and providing an anode fuel stream to the anode feed plenum,wherein the anode feed plenum is in fluid communication with the stackso that the anode fuel stream passes through the tubular cells to becomean anode exhaust.

In still another embodiment, the solid oxide fuel cell system furtherincludes an exhaust end tube sheet with an exhaust can dependingtherefrom. A sheath scalingly surrounds the feed tube and sealinglycouples to the exhaust end tube sheet so that an anode exhaust plenum isformed at the lower end of the stack within the exhaust can. As aresult, detrimental homogenous combustion will not occur at the bottomof the stack and a reducing environment is maintained about theelectrical interconnects. Further, in the event that the system werelaid on its side, the sheath and, thereby, the exhaust end tube sheetwould carry some of the load of the stack to help prevent damage.

The exhaust can also defines an anode exhaust hole, wherein the feedtube extends through the anode exhaust hole, and a cathode chamber candepending from the support plate and surrounding the stack and theexhaust can. The cathode chamber can defines an exhaust gas hole nearthe anode exhaust hole to form a region in which the anode exhaust andthe cathode exhaust mix to form a mixed exhaust stream.

In yet another embodiment, the subject technology is a solid oxide fuelcell system including a main plate, an elongated stack depending fromthe main plate, the stack having a first end adjacent the main plate anda second end opposing the first end. A cathode chamber can depends fromthe main plate and surrounds the elongated stack, the cathode chambercan defining an exhaust gases hole adjacent the second end. Arecuperator can depends from the main plate and surrounds the cathodechamber can to form a first annular gap there between and at least oneexhaust port near the first end of the stack. An outer can depends fromthe main plate and surrounds the recuperator can to form a secondannular gap there between and at least one inlet port near the first endof the stack for receiving an inlet cathode stream. A cathode feed tubereceives the inlet cathode stream near a second end of the stack suchthat a counter-flow recuperator is formed between the first and secondannular gaps by an exhaust stream passing from the exhaust gas hole tothe at least one exhaust gas port.

The solid oxide fuel cell may also include a feed can coupled to themain plate for defining an anode air stream plenum adjacent the firstend of the stack, the anode air stream plenum being in fluidcommunication with the stack as well as a CPOX reactor in fluidcommunication with the anode feed plenum for receiving a liquid fuel andproviding an anode fuel stream to the anode feed plenum. A thermalbalance may be controlled by adjusting a cathode flow rate through theat least one inlet port and a fuel feed rate into the stack. The solidoxide fuel cell system may also include a tail gas combustor between therecuperator can and cathode chamber can. The main plate may be planarand substantially circular. The outer can may be generally tubular witha largely open end and closed end. The recuperator can may be generallytubular with a largely open end and substantially closed end. Thecathode chamber can may be generally tubular with a largely open end andsubstantially closed end.

It should be appreciated that the present invention can be implementedand utilized in numerous ways, including without limitation as aprocess, an apparatus, a system, a device, and a method for applicationsnow known and later developed. These and other unique features of thesystem disclosed herein will become more readily apparent from thefollowing description and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

So that those having ordinary skill iN the art will more readilyunderstand how to make and use the same, reference may be had to thefollowing drawings.

FIG. 1 is a schematic view of a generator using a solid oxide fuel cell(SOFC) system with a hot zone.

FIG. 2 is a cross-sectional view of a SOFC system with an improved hotzone with improved reactant distribution in accordance with the subjecttechnology.

FIG. 3 is a cross-sectional view of another SOFC system with an improvedhot zone with improved reactant distribution in accordance with thesubject technology.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present invention overcomes many of the prior art problemsassociated with hot zone integration in fuel cell systems. Theadvantages, and other features of the systems and methods disclosedherein, will become more readily apparent to those having ordinary skillin the art from the following detailed description of certain preferredembodiments taken in conjunction with the drawings which set forthrepresentative embodiments. All relative descriptions herein such asinner, outer, upward, downward, top, bottom, left, right, up, and downare with reference to the Figures, and not meant ill a limiting sense.

Referring now to FIG. 2, a cross-sectional view of a SOFC system 200constructed in accordance with the subject technology is shown. The SOFCsystem 200 includes an elongated stack 202 that consists of a bundle oftubes or tubular cells 204. The tubular cells 204 are connected byinterconnects 206 in accordance with the technology disclosed inco-pending, co-owned U.S. patent application Ser. No. 11/895,333, filedAug. 24, 2007, entitled Electrical Interconnects for a Solid Oxide FuelCell Stack. The elongated stack 202 has the tubular cells 204 connectedin series on both ends but alternative versions may only be connected atonly one end. The SOFC tubes 204 are arranged in a concentric hexagonalpattern in two rows with the inner row having six SOFC tubes 204 and theouter row having twelve SOFC tubes 204. Each SOFC tube 204 has an anodeelectrode on the inside and a cathode electrode on the outside. Muchlarger stacks may be made by adding more SOFC tubes 204 in successiverings. The bundle of tubular cells 204 is retained in an outer can 210.The outer can 210 is surrounded by insulation 212 a-c to retain heattherein and, thus, form a hot zone 208 therein. The SOFC tubes 204 aremechanically supported by an anode feed end tube sheet 214 at a top endwithin the hot zone 208. If the SOFC system 200 were laid on its side,an exhaust end tube sheet 216 would carry some of the load and protectthe SOFC tubes 204 from breakage.

FIG. 2 includes arrows A-H to indicate flowpaths through the SOFC system200. The position and configuration of the arrows A-H are to beinformative as to how fluid passes though the SOFC system 200 and notmeant in a limiting sense. For clarity, only certain flowpaths have beendenoted by arrows A-H as would be appreciated by those of ordinary skillin the art based upon review of the subject disclosure. In general, theflow paths are cylindrically symmetric with regard to the central axisof the hot zone 208 except at the cathode air inlets 234.

Anode Flow

The CPOX reactor 218 intakes fuel and air via a feed port 220 for flowacross a CPOX catalyst 222 as denoted by arrow A. Fuel, such as propane,is premixed with air and reacted with ambient air over the CPOX catalyst222 to produce a SOFC fuel gas stream composed of primarily hydrogen,carbon monoxide and nitrogen. In alternative embodiments, the fuel isnot necessarily premixed with air. For example, the fuel may simply besprayed or otherwise vaporized with air and directed over the CPOXcatalyst 222.

Fuel gases from the CPOX reactor 218 are fed to the SOFC tubes 204 froman anode feed plenum 224 formed by a feed can 226 attached to the anodefeed end tube sheet 214 as denoted by arrows B. By positioning the CPOXreactor 218 above the anode feed plenum 224, liquid fuel may be sprayedonto the CPOX reactor catalyst 222.

By locating the CPOX reactor 218 at a boundary of the hot zone 208, theCPOX reactor 218 may extend partially upward out of the hot zone 208 oreven be fully outside the hot zone 218. By locating the CPOX reactor 218at the top of the hot zone 208, a diameter and length of the CPOXreactor 218 may be sized and configured to accept liquid fuel. Thus, theliquid fuel may be relatively cool until atomized, which advantageouslyprevents pre-ignition and alleviates fuel delivery problems,particularly those associated with diesel fuel.

Fuel gases (e.g., the reformed fuel) are consumed by electrochemicaloxidation in the SOFC tubes 204. Oxidation products and unutilized fuelare exhausted from the SOFC tubes 204 into an anode exhaust plenum 228formed between the exhaust end tube sheet 216 and the anode exhaust can230. Anode exhaust gas exits the anode exhaust plenum 228 through ananode exhaust hole 232 in the anode exhaust can 230 as denoted by arrowC.

Cathode Flow

Cathode air is fed to the hot zone 208 through air inlet ports 234 (onlyone air inlet port 234 shown) as denoted by arrow D. The cathode airpasses into an annular gap 236 formed between the outer can 210 and arecuperator can 238. Tie air inlet ports 234 may be channels orientednormal to the recuperator can 238 (as shown), tangential to therecuperator can 238, or at an angle in between. For tangentiallyoriented inlet ports 234, the inlet ports 234 arc preferably on opposingsides and directed in opposing Cartesian directions to impart arotational component to the cathode air feed. Without being limited toany theory, it is envisioned that a tangential orientation of the inletport 234 provides improved performance by improved circulation of thecathode air but any angle and orientation may be utilized.

After passing downward through the annular gap 236, the cathode air thenpasses into a center feed tube 240 as denoted by arrow E. The feed tube240 provides the cathode air to the stack 202 in a radial flow directionoutward from the feed tube 240, which is centrally located within thestack 202. The center feed tube 240 is perforated with holes 242 in apattern to provide a desired axial distribution of radial flow ofcathode air. The center feed tube 240 may have progressively smallerholes or fewer holes towards a top end in order to accomplish the evenaxial distribution. In another embodiment, the center feed tube 240 hasslots, which are varied in size, number and/or shape along a lengththereof. In still another embodiment, the center feed tube 240 is aporous material.

The cathode air flows in a radial direction from the center feed tube240 across the SOFC tubes 204 as denoted by arrow F. As the cathode airpasses across the SOFC tubes 204, oxygen is electrochemically consumedat the tube cathodes and transported as oxygen ions across theelectrolyte and into the tube anodes. Thus, oxygen-depleted air iscontained within a cathode chamber 244 defined between the tube sheet214 and support sheet 216, and surrounded by a cathode chamber can 246.As the cathode air approaches the cathode chamber can 246, the directionof the cathode air flow changes from a radial to an axial direction asexemplified by arrow F. The cathode air exhaust exits the cathodechamber 244 in a radial channel 248 between the cathode chamber can 246and the outside of the anode exhaust can 230.

The cathode air exhaust exits the radial channel 248 through an exhaustgases hole 250 formed in the cathode chamber can 246. Since the exhaustgases hole 250 is near and aligned with the anode exhaust hole 232,anode and cathode exhaust gases begin to mix in a region between theanode exhaust hole 232 and the exhaust gases hole 250 in the cathodechamber can 246.

The exhaust gases hole 250 also marks the beginning of a tail gascombustor 252 where unutilized fuel is further oxidized. The tail gascombustor 252 redirects the exhaust gases into a combustion zone with anoptional porous flame holder 254. The porous flame holder 254 can be aporous foam, metal, ceramic, or even a screen structure. The flameholder 254 can optionally be coated with catalyst material to promotecatalytic combustion of unutilized fuel gas.

Combusted exhaust gases leaving the tail gas combustor 252 enter achannel formed between the outside of the cathode chamber can 246 andthe inside of a recuperator can 238. The inside surface of recuperatorcan 238 and/or the outside surface of the cathode chamber can 246 mayoptionally be coated with an active combustion catalyst to provide asecond stage tail gas combustor that will complete the combustion ofunutilized fuel gases. Hot zone exhaust exits the hot zone throughexhaust ports 262 as denoted by arrow H.

The SOFC system 200 provides an efficient counter flow heat exchanger.Heat from the exhaust gases flowing upward along arrow H is transportedacross the cylindrical wall of the recuperator can 238 into the coldcathode air feed flowing downward along arrow D. Thus, the recuperatoror counter flow heat exchanger reduces heat loss in the exhaust byheating the inlet cathode air using heat from the exhaust. Heat loss tothe environment is further minimized by the feed end insulation 212 a,the recuperator insulation 212 b, and the combustor end insulation 212c.

As can be seen, mechanical support for the cells 204 is provided by theanode feed end tube sheet 214 and the exhaust end tube sheet 216. Theanode feed end tube sheet 214 supports the stack 202 within theinsulation 212 a-c. The outer can 210, cathode chamber call 246 andrecuperator can 238 may also depend from the anode feed end tube sheet214. In another embodiment, the outer can 210, cathode chamber can 246and recuperator can 238 are attached to each other at an outer mostradius near the exhaust ports. Lips on these cans 210, 238, 246 may beseam welded or clamped at the lips. The anode feed tube sheet 214 may besupported between the feed can 210 and the cathode chamber can 246. Theexhaust end tube sheet 216 may help to support the stack 202 and/or theexhaust can 230. The exhaust end of the stack is free to move axiallywith differences in thermal expansion between other components in thehot zone. One or more of the cans 210, 230, 238, 246 may includedimpling or similar attachments and modifications to fix radialorientations. For example, the exhaust can 230 and the cathode chambercan 246 may be dimpled to maintain a concentric relationship therebetween.

Start Up and Operation

Upon start up, the CPOX catalyst 222 is initially ignited with anelectrical igniter (not shown) that heats some of the CPOX catalyst 222to above an ignition temperature. Then, the tail gas combustor 252 isignited to produce a flame after the flame holder 254. The flame can beignited using a hot surface igniter or spark igniter (not shown). Thesetwo oxidation reactions produce heat for heating the stack 202 to anoperating temperature at which point electrical power can be drawn fromthe SOFC system 200.

In operation, stack temperature, which is measured by a thermocouple256, is controlled by balancing heat inputs against heat losses Heat isgenerated in the SOFC system 200 due to exothermic oxidation reactionsin the CPOX reactor catalyst 222 and also by the tail gas combustor 252and stack inefficiencies. Heat is lost through the insulation 212 a-cand ineffective recuperation of hot exhaust. In the SOFC system 200, thethermal balance can be controlled by adjusting the cathode air flowrate, which determines the amount of heat coming out in the exhaust.Also, the fuel feed rate into the hot zone 208 and electrical powerbeing removed significantly impact the thermal balance. For example, onecan turn off the load on the SOFC system 200 and reduce the fuel feed tochange the thermal balance. Additionally, the cathode air is typicallymoved by a blower 132 and the fuel feed rate controlled by a fuel pump130. Thus, the blower 132 and pump 130 can be used to maintain thermalbalance.

The SOFC system 200 is also well balanced thermally. The CPOX reactor218 and tail gas combustor 252 are both exothermic. By locating the CPOXreactor 218 and tail gas combustor 252 at opposing ends of the stack202, these heat sources are distributed within the SOFC system 200 toreduce the axial temperature variations.

As a large amount of heat is commonly lost through the insulation inprior art small generator systems, the outer tubes are commonly coolerthan the centralized tubes, which creates uneven radial temperatures.The SOFC system 200 also addresses this phenomenon by having therelatively cold air inlets 234 on the outside of the heat exchanger,whether it be counter or co-flow. Thus, the colder air envelops thestack 202 to provide an insulative effect and reduce the temperature upagainst the insulation. Although the cooler air absorbs heat, thecathode air passes into the center feed tube 240, as denoted by arrow E,is still relatively cooler than the central tubes 204. Thus, the cathodeair will provide some cooling effect on the central tubes 204 and, thus,the radial temperature will be more uniform.

To withdraw electrical power from the SOFC system 200, an anode powerlead 258 penetrates the feed can 226 and a cathode power lead 260penetrates the feed end tube sheet 214 near an outer diameter thereof.Various wire pairs, such as for the CPOX igniter and tail gas combustorigniter, may pass through the insulation 212 a-c boundary to attach tothe appropriate igniter, as needed. Alternatively, the wire pairs maypass through the feed port 220, inlet port 234 and/or exhaust port 262to avoid penetration of the insulation 212 a-c.

Preferably, low resistance wires are used for the anode lead 258 and thecathode lead 260 to carry the electric current. The leads 258, 260 passthrough the feed can 226 through a feed-through (not shown) thatmaintains a gas seal on each side of the feed can 226 and alsoelectrically insulates the feed can 226 from the leads 258, 260. Theanode power lead 258 passes through the feed can 226 such that the anodelead 258 is exposed to a hydrogen containing environment on the insideof the feed can 226 and an oxygen containing environment on the outsideof the feed can 226. Although silver and copper both have lowresistivities, copper will oxidize quickly at temperatures over 400° C.and silver, while stable in an oxidizing environment, has highsolubilities for both hydrogen and oxygen leading to mechanical failureswhen insoluble water is generated within the metal as noted in a paperby Singh, P., Yang, Z., Viswanathan, V., and Stevenson, J. W., 2004,entitled “Observations on the Structural Degradation of Silver DuringSimultaneous Exposure to Oxidizing and Reducing Environments,” J. Mater.Eng. Perform., 13, pp. 287-294.

In view of these problems, alternate materials such as nickel or hightemperature alloys like inconel have been used, but the higherresistivity of these metals undesirably requires a larger wire diameter.The current can also be carried through the material of the feed can226. To overcome these drawbacks, the SOFC system 200 preferably extendsthe wire feed through seal using a tube (not shown) such that the gasboundary is located outside the insulation, thus maintaining a cooltemperature for the portion of wire that is exposed to oxygen. As aresult, the SOFC system 200 can use either silver, copper or any otherelectrically conductive material that can withstand oxidizingenvironments at or around 250° C. as the current carrying anode powerlead.

Another Embodiment

Now referring to FIG. 3, another embodiment of a SOFC system is shown incross-section and referred to generally by the reference numeral 300. Aswill be appreciated by those of ordinary skill in the pertinent art, theSOFC system 300 utilizes similar principles to the SOFC system 200described above. Accordingly, like reference numerals preceded by thenumeral “3” instead of the numeral “2”, are used to indicate likeelements. The primary difference of the SOFC system 300 in comparison tothe SOFC system 200 is the addition of element(s) for improved flowdistribution and relocation of the cathode air inlet 334.

Achieving even anode flow distribution among all the SOFC tubes 304 isimportant for operation at high fuel utilization. As the SOFC system 300scales to different sizes and multiple rows of tubes 304, distributinggas flow through the tubes 304 can be enhanced by adding a distributiondevice 370. In the embodiment shown, the distribution device 370 is agas diffuser 372 in the anode feed end of the stack 302 below the CPOXreactor 322 and another gas diffuser 374 below the bottom end of thestack 302. Both diffusers 372, 374 are not necessarily needed in allapplications and either may accomplish the necessary flowre-distribution depending upon the particular application. The diffusers372, 374 consist of a plate perforated with holes. The diameter of thediffuser holes and their distribution in the plate can also be adjustedto control the gas flow distribution. Alternatively, the distributiondevice 370 may include restrictors, reshaping of existing surfaces, abaffle, various deflectors, a porous sheet, screen, or other materialthat helps distribute flow.

The distribution device 370 also includes a flow restrictor 378 in eachof the SOFC tubes 304 for improving gas flow. The restrictor 378 can beany device that imposes a controlled pressure drop through each tube304. Different pressure drops through restrictors in different tubescould be useful to overcome anything that might cause uneven pressuredrops through tubes before the restrictors are in place. Examples couldbe manufacturing or assembly tolerances, cracks in the tubes,intentional design for poor pressure matching between tubes in order toachieve cost reductions, weight savings or any other desirablecharacteristics. In addition, it is possible that the restrictors mightonly be used in certain tubes and not others to achieve the desired flowdistribution. Preferably, the restrictor 378 is an insert with acontrolled hole diameter through which the gas flows. Alternatively,porous plugs and/or perforated disks may be used. In one embodiment, therestrictors or like device are a configuration that has controllablepressure drop characteristics. Furthermore, the flow restrictor 378could be an integral part of the interconnect or attached to theinterconnect to aid in fixing the restrictor location. While the figureshows the restrictor 378 at the inlet end of the tubes 304, multiplerestrictors 378 could be used in various locations such as at the outletend or any place within the tube 304.

Still referring to FIG. 3, the cathode air inlet 334 is relocated awayfrom the exhaust ports 362 in order to provide more control over thetemperature distribution within the hot zone 308. The cathode air inlet334 is located closer to the outlet end of the stack 302. By sucharrangement, cooling from the cold cathode inlet air is provided nearthe tail gas combustor 352, which is typically the hottest location ofthe hot zone 308. As a result, axial temperature distribution may beaccomplished with acceptable reduction in the effectiveness of therecuperator. It is noted that the exhaust gases hole 350, if sizedproperly, may act as a flame holder for the first stage of the tail gascombustor 352.

The illustrated embodiments are understood as providing exemplaryfeatures of varying detail of certain embodiments, and therefore,features, components, elements, and/or aspects of the illustrations canbe otherwise combined, interconnected, sequenced, separated,interchanged, positioned, and/or rearranged without materially departingfrom the disclosed systems or methods. Additionally, the shapes andsizes of components are also exemplary and can be altered withoutmaterially affecting or limiting the disclosed technology. Accordingly,while the invention has been described with respect to preferredembodiments, those skilled in the art will readily appreciate thatvarious changes and/or modifications can be made to the inventionwithout departing from the spirit or scope of the invention as definedby the appended claims.

Incorporation by Reference

All patents, published patent applications and other referencesdisclosed herein are hereby expressly incorporated in their entiretiesby reference.

1. A solid oxide fuel cell system comprising: a main plate; an elongatedstack depending from the main plate, the stack having a first endadjacent the main plate and a second end opposing the first end; acathode chamber can depending from the main plate and surrounding theelongated stack, the cathode chamber can defining an exhaust gases holeadjacent the second end; a recuperator can depending from the main plateand surrounding the cathode chamber can to form a first annular gapthere between and at least one exhaust port; and an outer can dependingfrom the main plate and surrounding the recuperator can to form a secondannular gap there between and at least one inlet port for receiving aninlet cathode stream; and a cathode feed tube for receiving the inletcathode stream near a second end of the stack such that a counter-flowrecuperator is formed between the first and second annular gaps by anexhaust stream passing from the exhaust gas hole to the at least oneexhaust gas port.
 2. A solid oxide fuel cell as recited in claim 1,wherein the at least one exhaust port and the at least one inlet portare near the first end of the stack, the at least one inlet port islocated away from the at least one exhaust port in order to controlstack temperature more evenly, the cathode feed tube extends centrallythrough the elongated stack, and the cathode feed tube is attached tothe recuperator can, and further comprising a feed can coupled to themain plate for defining an anode feed plenum adjacent the first end ofthe stack, the anode feed plenum being in fluid communication with thestack; and a fuel processing reactor in fluid communication with theanode feed plenum for receiving a hydrocarbon fuel and providing ananode fuel stream to the anode feed plenum, wherein the main plate isplanar and substantially circular, the outer can is generally tubularwith a largely open end and closed end, the recuperator can is generallytubular with a largely open end and substantially closed end, and thecathode chamber can is generally tubular with a largely open end andsubstantially closed end.
 3. A solid oxide fuel cell as recited in claim1, wherein the at least one inlet port is two inlet ports that are onopposing sides, tangential to the recuperator can, and oriented inopposite directions.
 4. A solid oxide fuel cell as recited in claim 1,wherein a thermal balance is controlled by adjusting a cathode flow ratethrough the at least one inlet port and a fuel feed rate into the stack.5. A solid oxide fuel cell system as recited in claim 1, furthercomprising a tail gas combustor between the recuperator can and cathodechamber can, the tail gas combustor for oxidizing unutilized fuelpassing through the exhaust gases hole, wherein exhaust from the tailgas combustor is directed into the fist annular gap, wherein the tailgas combustor has a first stage near the second end of the stack and asecond stage in the first annular gap, the second stage includes anactive combustion catalyst coated on an inside surface of therecuperator call, and the second stage includes an active combustioncatalyst coated on an outside surface of the cathode chamber can.